Patch transfer and inspection apparatus

ABSTRACT

The invention provides an interlinked device for producing sealed packaging units, with a clocked delivery device for web-like material, with a separating device for separating in each case at least one portion of the web-like material, with a clocked packaging device, and with a sealing device, the sum of the stoppage intervals per cycle of the delivery device differing from the sum of the stoppage intervals per cycle of the packaging device, and a method for producing such a packaging unit. For this purpose, the device comprises an intermediate conveyor device which, in the material flow, is arranged between the delivery device and the packaging device. An optical inspection device is also arranged on the intermediate conveyor device and used at least for geometric inspection of the separated portion. With the present invention, a device and a method are disclosed for producing packaging units in an interlinked device, in which the content of the packaging unit can be inspected.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation-in-part application of U.S. ProvisionalApplication No. 61/125,505 filed Apr. 25, 2008, and claims the benefitof said U.S. Provisional Application.

BACKGROUND OF THE INVENTION

The invention relates to an interlinked device for producing sealedpackaging units, with a clocked delivery device for web-like material,with a separating device for separating in each case at least oneportion of the web-like material, with a clocked packaging device, andwith a sealing device, the sum of the stoppage intervals per cycle ofthe delivery device differing from the sum of the stoppage intervals percycle of the packaging device, and a method for producing such apackaging unit.

Sealed packaging units, which are used for example for therapeuticsystems or for wafers containing active substances, are in most casesproduced in an interlinked production process that ranges from themanufacture of the systems to the packaging in packaging units. Forexample, single-layer or multi-layer material webs are produced, shapedcuts are introduced, and the systems imprinted. During this manufacture,a so-called release liner, for example, is used as system carrier. It isonly directly before the packaging station that individual portions areseparated from this carrier for singulation of the systems and areplaced between the packaging material webs. They are then carried alongwith the packaging material webs and sealed within these by means of thesealing device.

The individual separated portion may have geometric defects orpositioning errors. For example, it may be too long or too short. It isalso possible for narrow portions to be inadvertently sealed inindividually or in addition to a geometrically correct portion. There isalso a danger of part of the separated portion falling into the area ofthe sealing seam. Inspecting the content of the packaging unit prior tothe packaging operation is not possible in the arrangement usedhitherto.

The object of the present invention is therefore to develop a device anda method for producing packaging units in an interlinked device, inwhich the content of the packaging unit can be inspected.

SUMMARY OF THE INVENTION

The invention provides an interlinked device for producing sealedpackaging units, with a clocked delivery device for web-like material,with a separating device for separating in each case at least oneportion of the web-like material, with a clocked packaging device, andwith a sealing device, the sum of the stoppage intervals per cycle ofthe delivery device differing from the sum of the stoppage intervals percycle of the packaging device, and a method for producing such apackaging unit. For this purpose, the device comprises an intermediateconveyor device which, in the material flow, is arranged between thedelivery device and the packaging device. An optical inspection deviceis also arranged on the intermediate conveyor device and used at leastfor geometric inspection of the separated portion. With the presentinvention, a device and a method are developed for producing packagingunits in an interlinked device, in which the content of the packagingunit can be inspected.

In the production process, a web-like starting material is delivered ina clocked manner. During a stoppage interval of the delivery device,portions of the web-like starting material are separated from theweb-like starting material by means of a separating device. An opticalinspection device inspects these portions at least geometrically on anintermediate conveyor device arranged downstream of the separatingdevice in the material flow. A lower packaging material web and an upperpackaging material web are delivered in a clocked packaging device. Theintermediate conveyor device transfers the portions between thepackaging material webs. During a stoppage interval of the packagingdevice, the packaging material webs are sealed in a sealing device suchthat the packaging unit is closed in a moisture-tight and aroma-tightmanner.

BRIEF DESCRIPTION OF THE DRAWINGS

Further details of the invention will become evident from the drawingsshowing exemplary embodiments of the invention as follows:

FIG. 1 shows schematically a device according to the invention forproducing packaging units;

FIG. 2 is a path-time diagram of the delivery device;

FIG. 3 is a path-time diagram of the intermediate conveyor device; and,

FIG. 4 is a path-time diagram of the packaging device.

DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS

FIG. 1 shows an interlinked device (1) for producing packaging units(80), for example for medical products such as transdermal therapeuticsystems (95) or wafers (95) containing active substances. The device (1)comprises a delivery device (10), a separating device (20), anintermediate conveyor device (30), an inspection device (40), apackaging device (50), and a sealing device (60). In this illustrativeembodiment, all of said parts (10, 20, 30, 40, 50, 60) of the device (1)are rigidly interlinked one after another in the material flow withoutbuffers. This means that any malfunction of a part (10, 20, 30, 40, 50,60) or in a part (10, 20, 30, 40, 50, 60) of the device (1) adverselyaffects the material flow and the availability of the whole device (1).

The starting material for the item (95) to be packaged is a web-likematerial (90) which is conveyed by means of the delivery device (10).The delivery device (10) for this purpose comprises an intermittentconveyor (11). The stroke cycle of an intermittent conveyor (11)comprises a delivery stroke and a return stroke. The return stroke is anidle stroke which runs counter to the conveying direction (5) and inwhich the load-bearing parts return to their starting position. In theillustrative embodiment shown here, the intermittent conveyor (11)comprises feeding pincers (12) which engage the web-like material (90)from below and from above, for example at its outer edges. Severalfeeding pincers (12) have, for example, a common drive mechanism foradvancing the material. In the illustrative embodiment, they are in eachcase clamped with spring loading by a compression spring (13). Ifappropriate, the clamping can also be effected via a common drivemechanism, or a common drive mechanism can effect both the clamping andthe advancing movement. Instead of using the feeding pincers (12), theweb-like material (90) can also be advanced by means of grippers orother intermittent conveyors (11).

In the illustrative embodiment, the separating device (20) comprises twointersecting knives (21, 22), of which one (21) is arranged above, andthe other (22) below, the web-like material (90).

To convey the web-like material (90), it is first of all clamped bymeans of the feeding pincers (12). The advancing drive mechanism, whichhas a predefined stroke, for example, then pushes the web-like material(90) in the direction of the separating device (20). As soon as the endposition of the stroke is reached, the separating device (20) separatesa portion (95) of the web-like material (90). This portion (95) is, forexample, a transdermal therapeutic system (95) or a wafer (95). Duringthe separating operation, the delivery device (10) is stopped. Thefeeding pincers (11) are now opened and, by means of the advancing drivemechanism, travel to the starting position arranged away from theseparating device (20). The next conveying cycle of the intermittentconveyor (11) now begins. If appropriate, the separating device (20) canalso be actuated only after every second advance cycle or after anotherwhole-number multiple of an advance cycle. This results from the ratioof the length of a wafer (95) to the advance stroke.

FIG. 2 shows a path-time diagram of the advance movement of the web-likematerial (90). In this diagram, an abrupt change of speed is assumed forreasons of simplicity, and the acceleration and deceleration paths andtimes are not shown. The time (t) is plotted on the abscissa, e.g. inseconds, and the path traveled (s) is plotted on the ordinates, e.g. inmillimeters. The gradient of the resulting curve—the mathematical firstderivation of the path function over time—is a measure of the speed ofadvance of the delivery device (10).

The web-like material (90) is advanced, for example, at constant speedas far as time point (121). From this time point (121), the web-likematerial (90) is stopped. For example, during a time interval (102) thatlasts up to time point (124), a portion (95) of the web-like material(90) is separated and the feeding pincers (12) are moved back to thestarting position relative to the device (1). They engage the web-likematerial (90) in the next segment. Starting from time point (124), theweb-like material (90) is conveyed onward in the direction of theseparating device (20). The conveying speed in the time interval (103)beginning at time point (124) corresponds to the conveying speed in thetime interval (101) between the origin of the coordinates and time point(121).

As the web-like material (90) is being conveyed, it passes through acutting plane defined by the separating device (20). The end lying atthe front in the conveying direction (5) places itself flat, forexample, on the moving intermediate conveyor device (30) and is taken upby the latter. The conveying speed of the intermediate conveyor device(30) corresponds, for example, to the conveying speed of the deliverydevice (10). After the time interval (102), which corresponds forexample to the quotient of the wafer length and the conveying speed ofthe delivery device (10), both the delivery device (10) and theintermediate conveyor device (30) are stopped, and the part of theweb-like material (90) passing through the cutting plane is cut off asportion (95).

The intermediate conveyor device (30) comprises a continuous conveyor(31) which is driven by means of a servo motor via a driving drum (32)and is guided by means of a guide drum (33). In the continuous conveyor(31), there is no reversal of the stroke direction. The conveyor meansis guided back during the conveying operation to its starting point. Theconveyor means (34) of this continuous conveyor (31) is, for example, acontinuously circling endless conveyor belt (34). The latter has, forexample, a plurality of apertures, for example having a mesh-likestructure. A suction device (36) is arranged below the upper load strand(35) of the conveyor belt (34). In the area between the driving drum(32) and the guide drum (33), this suction device (36) sucks theportions (95) lying on the load strand (35), which load portions (95)are thus pressed onto the load strand (35) and are conveyed in theconveying direction (5) without slip.

FIG. 3 shows a simplified path-time diagram of the portions (95)conveyed by means of the intermediate conveyor device (30). The abscissaand ordinate scales correspond for example to the corresponding scalesin FIG. 2. Starting from the origin of the coordinates (the origin ofthe time axis in FIG. 3 corresponds, for example, to the origin of thetime axis in FIG. 2), the path change per unit of time is constant up toa time point (121), as a result of which the path-time diagram isdepicted as a straight line. The constant gradient, which corresponds toa constant speed, is identical, for example, to the gradient of thecurve shown in FIG. 2 between the origin of the coordinates and timepoint (121) and in the time interval (103) following time point (124).

In the time interval (105) between time point (121) and time point(122), the conveying operation of the intermediate conveyor device (30)is interrupted. In this time interval (105), the separating device (20)cuts off a portion (95) of the web-like material (90).

Starting from time point (122), the intermediate conveyor device (30)conveys the separated portion (95) onward. In the following timeinterval (106) in which the delivery device (10) is stopped, theseparated portion (95) travels a distance, for example, that correspondsto the length difference of a packaging unit (80) and of a portion (95).In this time interval (106), the conveying speed of the portions (95)can be higher or lower than the conveying speed of the web-like material(90) outside of the stoppage times.

At time point (124), a new cycle then begins, for example one that isconstructed analogously to the cycle beginning at the origin of thecoordinates. The cycle length of the delivery device (10) is identicalto the cycle length of the intermediate conveyor device (30). The sum ofconveying intervals (101; 103) and of stoppage intervals (102) of thedelivery device (10) thus corresponds to the sum of the conveyingintervals (104, 106; 107) and stoppage intervals (105) of theintermediate conveyor device (30).

Instead of a continuous conveyor (31), the intermediate conveyor device(30) can also comprise an intermittent conveyor. The return stroke timesof an intermittent conveyor then lie in the stoppage interval (105) ofthe intermediate conveyor device (30) described.

An inspection device (40) is arranged above the load strand (35). Itcomprises, for example, an optical camera (41) which is connected, forexample, to a comparator unit (not shown here). By means of thiscomparator unit, the geometric dimensions of the surface (96) of eachportion (95) lying on the conveyor belt (34) are compared with a storedset-point value during the stoppage interval (105) of the intermediateconveyor device (30). If the inspected portion (95) is too large or toosmall, or if it is lying askew on the conveyor belt (34), it is marked,for example, or ejected. The imprinting of the portion (95) can also bemonitored by means of this inspection device (40).

The inspection of a portion (95) takes place, for example, in a stoppageinterval during the cycle following its separation stoppage interval(105) Accordingly, the distance between the center line (45) of theinspection device (40) and the separating device (20) is the sum of thelength of a packaging unit (80) and half the length of a portion (95) orthe sum of the whole-number multiple of the length of a packaging unit(80) and half the length of a portion (95). The inspection device (40)can be adjusted in the lengthwise direction of the device (1) in orderto adapt the latter to another length of packaging unit (80) or toanother portion length (95).

It is also conceivable for the inspection to be carried out during theconveying of the intermediate conveyor device (30). In this case, theposition of the inspection device (40) relative to the separating device(20) can be chosen freely.

As soon as the portions (95) conveyed by means of the intermediateconveyor device (30) have left the area of influence of the suctiondevice (36), they lie only loosely on the load strand (35) of theconveyor belt (34). On reaching the driving drum (32), they aretransferred, flat for example, onto the packaging device (50). Theindividual portions (95) reach the packaging device (50) in a clockedsequence. Here, the time intervals between the times of arrival of theindividual portions (95) at the packaging unit (50) are constant. Since,in this illustrative embodiment, each portion (95) is received directlyby the packaging device (50), without waiting time, there is no bufferand no waiting line.

The packaging device (50) comprises an upper packaging material web(51), a lower packaging material web (52), and an intermittent conveyor(58) with feeding pincers (59). The upper and lower packaging materialwebs (51, 52) are each wound in lengths of several hundred meters ontoreels (53, 54) and each have a width of between 250 millimeters and 2500millimeters depending on the number of packaging units (80) produced inparallel. The lower packaging material web (52) is guided from the reel(54) to the transfer site (57), e.g. via a guide roller (56). At alocation offset from this in the conveying direction (5), the upperpackaging material web (51) is guided via a guide roller (55) into theconveying direction (5) parallel to the lower packaging material web(52).

Next to the site of transfer to the packaging device (50), theindividual portion (95) lies on the lower packaging material web (52).The feeding pincers (59), configured analogously for example to thefeeding pincers (12) of the delivery device (10), convey the packagingmaterial webs (51, 52), equipped with the portions (95), in theconveying direction (5). In this case, for example, an advance equal tothe length of a packaging unit (80) takes place in each cycle. Thefeeding pincers (59) can also be configured such that the advance equalto the length of a packaging unit (80) takes place in two cycles or inseveral whole-number cycles. The length of a packaging unit (80)corresponds to the sum of the length of a portion (95) and of bothprotruding areas of the packaging material webs (51, 52), whichprotruding areas are oriented in the longitudinal direction of thedevice (1) shown in FIG. 1 and are used for sealing.

During stoppage of the intermittent conveyor (58), the feeding pincers(59) are moved back to their starting position in order to continueconveying. As soon as the conveying path corresponds to the length of apackaging unit (80), the sealing device (60) is closed. For example, bymeans of an upper part (61) and lower part (62) of the sealing device(60), the upper and lower packaging material webs (51, 52) are sealedtogether, for example with simultaneous heating, to form amoisture-tight and aroma-tight closure. In the illustrative embodiment,the sealing is carried out at four seams surrounding the individualportion (95), resulting in what is called a four-edge sealed bag. Thelatter is separated from the packaging material webs (51, 52) in adownstream separating station not shown here.

The position of the sealing device (60) relative to the device (1) canbe adjusted, for example. In this way, the device (1) can be adapted todifferent portion and/or package lengths.

FIG. 4 shows a simplified path-time diagram of the packaging device(50). The scales of the abscissa and of the ordinates in this figurecorrespond, for example, to the abscissa and ordinates scales of FIGS. 2and 3. The origin of the time axis in FIG. 4 corresponds, for example,to the origin of the time axis in FIGS. 2 and 3.

The transfer of a portion (95) between the packaging material webs (51,52) at the transfer site (57) is described on the basis of the timeinterval (110-112) delimited by time points (122) and (126).

After a stoppage, the conveying operation of the packaging device (50)begins, for example, at time point (122). Starting from time point(123), a portion (95) is transferred to the packaging device (50) in theconveying interval (111). This transfer ends, for example, at time point(125). However, the intermittent conveyor (58) continues to conveythroughout the subsequent time interval (112). The end position of thestroke of the intermittent conveyor (58) is reached at time point (126).The path covered by the packaging webs (51, 52) throughout thisconveying interval (110-112) corresponds to the length of a packagingunit (80). The paths traveled in the time intervals (110) and (112) inthe illustrative embodiment correspond to the length of the forward andrear sealing areas (81, 82) in the conveying direction (5). The pathtraveled in the time interval (111) by the packaging material webs (51,52), which are moved in synchrony, for example with a constant conveyingspeed, corresponds to the length of a portion (95).

The time point (126) is followed by a stoppage interval whose lengthcorresponds to the stoppage interval (109). The sealing of the packagingmaterial webs (51, 52) and the return stroke of the intermittentconveyor (58) take place, for example, during this stoppage interval(109). This stoppage interval (109) is not identical to the stoppageinterval (102) of the delivery device (10). It is shorter in theillustrative embodiment. A new cycle of the packaging device (50) beginsafter the stoppage interval (109).

The transfer of the portion (95) at the transfer site (57) can also beinterrupted by a stoppage of the conveyor devices (30, 58).

The distances (99) between the portions (95) on the intermediateconveyor device (30) correspond to the length of two sealing areas (81,82), which is the difference between the length of the packaging unit(80) and of an individual portion (95). A sealing area (81; 82)comprises the sealing seam and the protruding area of the correspondingpackaging materials (51, 52). In relation to the delivery device (10),this means that the stoppage interval (102) of the delivery device (10)is equal to the sum of the stoppage interval (109) of the packagingdevice (50) and the quotient of the distance (99) and the conveyingspeed of the intermediate conveyor device (30). The conveying speed ofthe intermediate conveyor device (30) corresponds in the illustrativeembodiment to the conveying speed of the packaging device (50). Thesetwo speeds can differ from each other, e.g. by ±3 percent. They aretherefore at least approximately the same.

To control the device, the packaging device (50) comprises, for example,an incremental sensor (not shown here). By means of this incrementalsensor, for example, a clock signal of the packaging device (50), e.g.the end of the sealing operation, is forwarded to an evaluation device.From this signal, it is then possible to derive a control signal, forexample, for the servomotor of the intermediate conveyor device (30).This signal can also be used to control the ratio between stoppageinterval (102) and conveying interval (101; 103) of the delivery device(10). Exact positioning of the individual portion (95) between thepackaging material webs (51, 52) is thus ensured.

The intermediate conveyor device (30) can comprise a buffer. Forexample, the suction device (36) then covers only a partial area of theload strand (35). A catch arranged outside the area of action of thesuction device (36), and controlled by the packaging device (50) forexample, then releases in each case one portion (95) for furtherprocessing.

It is also conceivable for the individual conveyor devices (10, 30, 50)to operate at different heights. For example, the separating device (20)is then arranged above the intermediate conveyor device (30) and theintermediate conveyor device (30) is arranged above the lower packagingmaterial web (52). In such an embodiment, the separated portion (95)then falls onto the intermediate conveyor device (30) and from thelatter onto the lower packaging material web (52). In such anembodiment, the conveying speeds of the individual conveyor devices (10,30, 50) can be different. For example, the stoppage interval (109) ofthe packaging device (50) can be greater than the stoppage interval(102) of the delivery device (10). However, the cycle interval—the sumof the respective conveying interval and of the respective stoppageinterval—at least of the packaging device (50) and of the deliverydevice (10) is approximately equal. Variations can be compensated, forexample, by means of the buffer described above.

If appropriate, the inspection device (40) can also control thepackaging device (50). In such an embodiment, for example, the detectionof a portion (95) by means of the inspection device (40) triggers a newcycle of the packaging device (50). Combinations of the describedillustrative embodiments are also conceivable.

The following is a list of reference signs used herein:

-   1 device-   5 conveying direction-   10 delivery device-   11 intermittent conveyor-   10 12 feeding pincers-   13 compression spring-   20 separating device-   21 knife, top-   15 22 knife, bottom-   30 intermediate conveyor device-   31 continuous conveyor-   32 driving drum-   20 33 guide drum-   34 conveyor means, conveyor belt-   35 load strand-   36 suction device-   25 40 inspection device-   41 camera-   45 center line-   30 50 packaging device-   51 upper packaging material web-   52 lower packaging material web-   53 reel-   54 reel-   35 55 guide roller-   56 guide roller-   57 transfer site-   58 intermittent conveyor-   59 feeding pincers-   60 sealing device-   61 upper part of (60)-   62 lower part of (60)-   80 packaging units-   81 seal area, forward-   82 seal area, rear-   90 web-like material-   95 portions, transdermal therapeutic systems, wafers, items to be    packaged-   96 surface-   99 distances-   101 time interval, conveying interval-   102 stoppage interval-   103-104 time interval, conveying interval-   105 stoppage interval-   106-108 time interval, conveying interval-   109 stoppage interval-   110-112 time interval, conveying interval-   121-126 time points-   s path-   t time

1. An interlinked device (1) for producing sealed packaging units (80),the device (1) including a clocked delivery device (10) adapted to carrya web-like material (90), the clocked delivery device (10) having atleast one stoppage time interval (102) per cycle, a separating device(20) operatively connected to the clocked delivery device (10) andadapted to separate in each case at least one portion (95) of theweb-like material (90), a clocked packaging device (50) operativelyconnected to the clocked delivery device (10) and adapted to place anupper packaging material web (51) and a lower packaging material web(52) on the at least one portion (95) of the web-like material (90), theclocked packaging device (50) having at least one stoppage time interval(109) per cycle, a sealing device (60) operatively connected to theclocked packaging device (50) and adapted to seal the upper packagingmaterial web (51) and the lower packaging material web (52) on to the atleast one portion (95) of the web-like material (90), the sum of thetime of the stoppage intervals (102) per cycle of the delivery device(10) differing from the sum of the time of the stoppage intervals (109)per cycle of the packaging device (50), an intermediate conveyor device(30) adapted to carry the at least one portion (95) of the web-likematerial (90), the intermediate conveyor device operatively arrangedbetween the delivery device (10) and the packaging device (50), and aninspection device (40) adapted to inspect the surface (96) of the atleast one portion (95) of the web-like material, the inspection device(40) operatively arranged with the intermediate conveyor device (30) forat least geometric inspection of the at least one portion (95) of theweb-like material (90).
 2. The device as claimed in claim 1, wherein thedelivery device (10), the intermediate conveyor device (30) and thepackaging device (50) are all adapted to have conveying speeds at leastapproximately the same outside of the stoppage intervals (102, 109). 3.The device as claimed in claim 1, wherein the delivery device (10)further comprises an intermittent conveyor (11).
 4. The device asclaimed in claim 1, wherein the sum of the time of the stoppageintervals (102) per cycle of the delivery device (10) is greater thanthe sum of the time of the stoppage intervals (109) per cycle of thepackaging device (50).
 5. The device as claimed in claim 1, wherein theinspection device (40) comprises a camera (41).
 6. The device as claimedin claim 1, wherein the intermediate conveyor device (30) furthercomprises a conveyor belt (34) and a suction device (36) in operativerelationship with the conveyor belt (34).
 7. The device as claimed inclaim 1, wherein the packaging device (50) further comprises anincremental sensor adapted to control at least the delivery device (10)and/or the intermediate conveyor device (30).
 8. A method for producingsealed packaging units (80) in an interlinked device (1), said methodcomprising: delivering a web-like starting material (90) in a clockedmanner, separating portions (95) of the web-like starting material (90)from the web-like starting material (90) by means of a separating device(20) during a stoppage time interval (102) of the delivery device (10),inspecting the portions (95) with an inspection device (40) at leastgeometrically on an intermediate conveyor device (30) arrangeddownstream of the separating device (20) in the material flow,delivering a lower packaging material web (52) and an upper packagingmaterial web (51) to the portions (95) by a clocked packaging device(50), transferring the portions (95) by the intermediate conveyor device(30) between the packaging material webs (51, 52), and sealing thepackaging material webs (51, 52) onto each other in a sealing device(60) such that the packaging unit (80) is closed in a moisture-tight andaroma-tight manner during a stoppage time interval (109) of thepackaging device (50).
 9. The method as claimed in claim 8, whereinconveying speeds of the delivery device (10), of the intermediateconveyor device (30) and of the packaging device (50) are at leastapproximately the same outside of the stoppage intervals (102, 109). 10.The method as claimed in claim 8, wherein the stoppage time interval(109) per cycle of the packaging device (50) is shorter than thestoppage time interval (102) per cycle of the delivery device (10).